• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.12
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• pp.24-29
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• 2021

Recently, owing to the high demand for eco-friendly cars in the automotive industry, noise and vibrations have become major challenges. The use of laminated damping steel is increasing in response to these demands. Laminated damping steel is primarily used in sound insulation plates. The vibration energy is converted into thermal energy due to the viscoelastic resin being located between two steel sheets and being able to damp the vibrations when an external force, such as, noise or vibration is applied to the steel plate. Laminated damping steel is chiefly applied to dash panels in automotive body parts, and because of its structure, junction technology for bonding with other components is necessary. However, there has not been sufficient research conducted on junctions. In this study, regardless of the electrode shape, in the range of 4.0 ~ 8.0 kA welding current, the same welding force and welding time were applied which were 2.8 kN and 200 m/s (12 cycles) and the tensile shear load and nugget size were analyzed after the resistance spot welding between different materials of laminated damping steel with a thickness of 1.035 mm. The results show that in the range of 5 ~ 8 kA welding current, 1.035 mm laminated damping steel meets the MS181-15 standard, which is the technical standard of Hyundai-Kia Motors.

• Proceedings of the KSME Conference
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• 2004.11a
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• pp.314-318
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• 2004

This research is conducted to investigate weldability characteristics with various welding conditions on the 4 lap spot welded joint of structural steel sheets in automobile. The relationship between the tensile-shear strength and the indentation depth has been investigated to evaluate the weldability and the optimum welding conditions. The welding current and the welding time have a greatly affect to the tensile-shear strength compared to the electrode force. It was found that the indentation depth has a relatively close relationship with the expulsion occurrence. The optimum welding conditions were proposed for the 4 lap spot welded joint.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.763-768
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• 2002

This paper presents a mathematical model predicting the temperature distribution in rotating GMA welding. The bead width increases with rotation frequency at the same rotation diameter because the molten droplets are deflected by centrifugal force. The numerical solution is obtained by solving the transient three-dimensional heat conduction equation considering the heat input from the welding arc, cathode heating and molten droplets. Generally in GMA welding the heat input may be assumed as a normally distributed source, but the droplet deflection causes some changes in the heat input distribution. To estimate the heat flux distribution due to the molten droplet, the contact point where the droplet is transferred on the weld pool surface is calculated from the flight trajectory of the droplets under the arc plasma velocity field obtained from the arc plasma analysis. The numerical analysis shows a tendency of broadened bead width and shallow penetration depth with the increase of rotating frequency. The simulation results are in good agreement with those obtained by the experiments under various welding conditions.

• Journal of Welding and Joining
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• v.28 no.4
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• pp.81-86
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• 2010

In resistance spot welding, regardless of the optimal condition, bad weld quality was still produced due to complicated manufacturing processes such as electrode wear, misalignment between the electrode and workpiece, poor part fit-up, and etc.. Therefore, the goal of this study was to measure the process signal which contains weld quality information, and to develop the process fault monitoring system. Welding force signal obtained through variety experimental conditions was analyzed and divided into three categories: good, shunt, and poor fit-up group. And then a monitoring algorithm made up of an artificial neural network that could estimate the process fault of each different category based on pattern was developed.

• International Journal of Korean Welding Society
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• v.3 no.2
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• pp.7-14
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• 2003

During the manufacture of a ship, longitudinal deformation is produced by fillet welding on the Built­Up beam used to improve the longitudinal strength of a ship. This deformation needs a correcting process separate from a manufacture process and decreases productivity and quality. This deformation is caused by welding moment, which is the value multiplied the shrinking force due to welding by the distance from the neutral axis on a cross section of Built­Up beam. This deformation can be offset by generating a moment which is the same magnitude with and is located in an opposite direction to the welding moment on web plate by induction heating. Accordingly, this study clarifies the creation mechanism of the longitudinal deformation on Built­Up beam with FEM analysis and presents the preventative method of this deformation by induction heating basing the mechanism and verifies its validity through analysis and experiments. The induction heating used here is performed by deciding its location and quantity with experiments and simple equations and by applying them to a real structure.

• Journal of Welding and Joining
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• v.26 no.1
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• pp.56-62
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• 2008

In this paper, elastic and plastic adhesion index was very important in deciding adhesive characteristics and varying elastic and plastic index, dimensionless load and pull-off force were analyzed and simulated. Finally, using AFM, experimental surface roughness parameters of substrates and pull-off force between tip and substrates were produced. Using these values, pull-off forces were calculated and were compared with experimental pull-off forces. Through simulation and experiment, it was found that interaction of asperity also had very important influence on adhesive contact.

• Journal of Welding and Joining
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• v.15 no.4
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• pp.154-165
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• 1997

Abrasive wear characteristics of high Cr white cast iron-based hardfacing were investigated using the rubber wheel abrasion wear test method according with the ASTM G65-85. Mild steel was also tested for comparison with high Cr cast iron hardfacing. Wear experiments, where the applied force, wheel revolution rate and abrasive powder feed rate were selected as test valuables, were planned and analyzed by response surface method to evaluate wear statistically and quantitatively. Weight loss of high Cr cast iron hardfacing was mostly affected by the applied force and wheel revolution rate, and little by the powder feed rate. Weight loss of mild steel was greatly affected by the wheel revolution rate and powder feed rate, and slowly and steadily increased with the applied force. Abrasive wear mechanism of high Cr cast iron and mild steel was discussed in the light of the wear test results.

• Journal of Mechanical Science and Technology
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• v.16 no.4
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• pp.501-511
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• 2002

This paper presents a study of the effect of rolling temperature, roll gap (pass height), initial specimen size and steel grades of specimens on the roll force in round-oval-round pass sequence by applying approximate method and verifications through single stand pilot rod rolling tests. The results show that the predicted roll forces are in good agreement with the experimentally measured ones. The approximate model is independent of the change of roll gap, specimen size and temperature. Thus, the generality of the prediction methodology employed in the approximate model is proven. This study also demonstrates that Shida's constitutive equation employed in the approximate model needs to be corrected somehow to be applicable for the medium and high carbon steels in a lower temperature interval (700∼900$\^{C}$).

• Journal of Welding and Joining
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• v.15 no.5
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• pp.84-91
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• 1997

The metal transfer phenomenon of the pulsed-GMAW is simulated by formulating the electromagnetic force incorporated with the Volume of Fluid algorithm. The free surface profiles, pressure and velocity distributions within the drop are computed numerically. Axial velocity and acceleration generated during peak current period are found to have a significant effect on drop detachment. Therefore, the accelerated inertia force becomes one of important factors affecting metal transfer in the pulsed-GMAW. When the pulse current parameters are selected properly, the molten drop is detached just after current pulse, and the operating range of the pulsing frequency increases with higher peak current and duty cycle. Calculated operating ranges show reasonably good agreements with the available experimental data.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.4
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• pp.613-618
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• 2012

The Ultrasonic metal welding is used in the solid-phase welding method at room temperature or low temperature state. In welding process, the high frequency vibration energy is delivered to the welding part under the constant pressure for welding. In this study, we aimed to design and manufacture a 40,000 Hz band horn through finite element analysis. By performing modal analysis and harmonic response analysis, the modal analysis result is that the horn frequency was 39,599Hz and the harmonic response result that the horn frequency was 39,533Hz. These results were similar. In order to observe the designed horn's performance, about 4,000 voltage data was obtained from a light sensor and was analyzed by FFT analysis using Origin Tool. The result RMS amplitude was approximately $8.5{\mu}m$ at 40,000Hz, and maximum amplitude was $12.3{\mu}m$. Using this manufactured horn along with an ultrasonic metal welder and tension tester, the weldability of Cu sheets was evaluated. The maximum tensile force was 66.53 N in the welding condition of 2.0 bar pressure, 60% amplitude, and 0.32 s welding time. In excessive welding conditions, it was revealed that weldability is influenced negatively.